VNR VIGNANA JYOTHI INSTITUTE OF ENGINEERING & TECHNOLOGY

Department of Mechanical Engineering

IV B.Tech II Semester (ME)

Academic Year 2016-17

Academic Plan

1. Industrial Engineering and Management

2. Unconventional Machining processes

3. Metal Casting Technology

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 VNR VIGNANA JYOTHI INSTITUTE OF ENGINEERING & TECHNOLOGY
(Autonomous)

DEPARTMENT OF MECHANICAL ENGINEERING

IV B. Tech, II Semester (Mechanical Engineering)

Subject : Industrial Engineering and Management
Subject Code : MED1138
Academic Year : 2016 – 17
Number of working days : 64
Number of Hours / week :4
Total number of periods planned : 64
Name of the Faculty Member: Dr.S.SHYAM SUNDER RAO

UNIT : I

Syllabus:
INTRODUCTION TO INDUSTRIAL ENGINEERING AND MANAGEMENT:
Concept of Industrial Engineering (I.E),History and Development of I.E, Role
of I.E, Applications of I.E, Production Management vs I.E, Principles of
Management, Functions of Management, Taylor's Scientific Management,
Maslow's Theory of Human Needs, Leadership Styles, Principles of
Organization, Types of Organization Structures their Merits and Demerits,
Entrepreneurship.

Learning Objectives: After completion of the unit, the student must able to:
 Explain Importance of Industrial Engineering
 Know the history of IEM and list the different viewpoints managerial
functions.
 Differentiate between IEM and production management.
 Explain the concept of Leadership Styles and theories of leadership.
 Describe various organization Structures and their merits and
demerits.
 Identify the importance of management
Lecture Plan
S.No. Description of Topic No. of Hrs. Method of
Teaching
Necessity and importance of IEM 1st & 2nd
1. PPT
hour
Role and applications of IEM 3rd & 4th Black board +
2.
hour PPT
3. History and development of IEM 5 hour
th Black board
4. Difference between the production 6th hour Black board +

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 management and IEM PPT
Principle and function of
5. 7th hour Black board
management
Taylor's Scientific Management Black board +
6. 8th hour
principle PPT
Maslow's Theory of Human Needs 9th & 10th Black board +
7.
hour Video
8. Leadership Styles 11th hour Black board
Principles of Organization, Types of
Black board +
9. Organization Structures their Merits 12th hours
Video
and Demerits
Entrepreneurship 13th & 14th
10. Black board
hour

UNIT : II
Syllabus:
PRODUCTION AND OPERATIONS MANAGEMENT:
Plant Location, Principles of Plant Layout, Different Types of Plant Layouts,
different Types of Production Systems, Travel Chart Technique, Simple
Problems on Assembly Line Balancing.
Production Planning and Control: Production Cycle, Product Design and
Development, Production Planning and Control Techniques, Simple
problems.

Learning Objectives: After completion of the unit, the student must able to:
 Explain plant location
 Analyze the different types of layouts.
 Solve problems on line balancing.
 Explain the production cycle.
 Apply the different techniques of in the industry.

S.No. Description of Topic No. of Hrs. Method of

Teaching
1. Importance of Plant Location 15&16th hour PPT + Video
Principles of Plant Layout 17&18th
2. Black board
hours
Different Types of Plant Layouts 19th & 20th Black board +
3.
hour Video
Types of production systems 21 & 22th
th
4. Black board
hours
Travel Chart Technique 23th & 24th
5. Black board
hours
6. Describe Production Cycle 25h & 26th Black board +

3
 hours PPT
Production Planning and Control
27th & 28h
7. Black board
Techniques hours
Simple problems on assembly line 29th & 30th Black board +
8.
hour Video

UNIT : III
Syllabus:
WORK STUDY:
Concept of Productivity, Method Study - Basic steps in Method Study,
Process Charts, Diagrams, Models and Templates, Principles of Motion
Economy, Micro Motion Study, Therbligs, SIMO Chart. Work Measurement -
Stop Watch Procedure of Time Study, Performance Rating, Allowances, Work
Sampling, Simple Problems.
MATERIALS MANAGEMENT:
Introduction, Purchasing, Objectives of Purchasing Department, Buying
Techniques, Purchase Procedure, Stores and Material Control, Inventory
Control, EOQ Model(Simple Problems), Supply Chain Management.
Quality Control - Statistical Quality Control, Control Charts for Variables
and Attribute, Simple Problems, Acceptance Sampling, Deming's
Contribution to Quality. Total Quality Management, Taguchi’s Quality
Engineering, Value Analysis and Value Engineering

Learning Objectives: After completion of the unit, the student must able to:
 State the types of fluid measuring devices.
 Explain working of Pitot tube, Venturimeter, Office meter, Nozzle
 Explain Classification of Orifices and Mouthpieces
 Estimate discharge through submerged orifices
 Estimate discharge through external and internal cylindrical
mouthpiece
Lecture Plan
S.No. Description of Topic No. of Hrs. Method of
Teaching
Concept of Productivity and basic Black board +
1. 31st hour
steps in method study Video
Process Charts, Diagrams Black board +
2. 32rd hour
Video
Principles of Motion Economy, Micro
Black board +
3. 33th hour
Motion Study Video

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 Work Measurement - Stop Watch
Procedure of Time Study, Black board +
4. 34th hour
Performance Rating, Allowances, Video
Work Sampling, Simple Problems
Objectives of Purchasing Black board +
5. 35th hour
Department, Buying Techniques, Video
Purchase Procedure, Stores and
6. 36th hour Black board
Material Control

7. Inventory Control 37th hour Black board

8. EOQ simple problems 38th hour Black board
Supply Chain Management 39th & 40th
9. Black board
hour
Quality Control - Statistical Quality
10. 41st hour Black board
Control
Control Charts for Variables and
Black board +
11. 42nd hour
Attribute PPT
Simple Problems on control charts 43rd & 44th
12. Black board
hour
Acceptance Sampling 45 & 46th
th
13. Black board
hour
Deming's Contribution to Quality 47 & 48th
th
14. Black board
hour
Total Quality Management Black board +
15. 49th hour
PPT
Value Analysis and Value
16. 50th hour Black board
Engineering
Taguchi’s Quality Engineering, Black board +
17. 51st hour
PPT

UNIT: IV
Syllabus:
MARKETING:
Functions of Marketing, Marketing Mix, Product Life Cycle. Channels of
Distribution and Sales Management.
Manufacturing planning: MRP, MRP-II, JIT, CIM
Materials Handling- Principles, Concept of Unit Load, Containerization,
Pelletization, Selection of Material Handling Equipment, Applications of Belt
Conveyors, Cranes, Forklift Trucks in Industry.

Learning Objectives: After completion of the unit, the student must able to:

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  Explain the types of Functions of Marketing.
 Explain the Channels of Distribution
 Understand the manufacturing planning MRP, MRP-II, JIT, CIM
 Analyze and apply the material handling equipments.
 Describe about Pelletization
Lecture Plan

S.No. Description of Topic No. of Hrs. Method of

Teaching
1. Functions of Marketing 52nd hour PPT + Video
Product Life Cycle 53rd Black board +
2.
&54thhour Video
Channels of Distribution and Sales 55th
3. Black board
Management. &56thhour
MRP Black board +
4. 57th hour
Video
5. JIT, CIM 58th hour
Selection of Material Handling
Equipment, Applications of Belt Black board +
6. 59th hour
Conveyors, Cranes, Forklift Trucks PPT
in Industry.

UNIT : V

Syllabus:
HUMAN RESOURCES MANAGEMENT (HRM):
Concepts of HRM, Basic Functions of HR Manager: Manpower Planning,
Recruitment, Selection, Training and Development, Placement, Wage and
Salary Administration, Promotion, Transfer, Separation, Performance
Appraisal.
INDUSTRIAL RELATIONS:
Trade Unions, Industrial Disputes, Strikes, Lock-Out, Picketing, Gherao,
Settlement of Industrial Disputes, Collective Bargaining, Industrial Dispute
Act 1947 and Factories Act 1948.

Learning Objectives: After completion of the unit, the student must able to:

 Explain energy loses in pipes, Darcy – weisbach equation

 Describes Hydraulic power transmission through a pipe; Siphons
 Explain Pipes in series, parallel & branched pipes; water hammer.

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 Describe the Reynold’s experiment.
 Explain about Characteristics of Laminar flow through circular pipes.
 Solve problems on pipe flow and Laminar flow through pipes
Lecture Plan

S.No. Description of Topic No. of Hrs. Method of

Teaching
1. Concepts of HRM 60 hour Black board
2. Basic Functions of HR Manager 61th hour PPT + Video
3. Wage and Salary Administration 62th hour Black board
4. Trade Unions, Industrial Disputes 63rd hour Black board
Industrial Dispute Act 1947 and
5. Factories Act 1948. 64st hour Black board +
Overview of last unit PPT

TEXT BOOKS
1. Aryasri: Management Science, TMH, New Delhi, 2009
2. Industrial Engineering Management, by Dr. O. P .Khanna.
REFERENCES:
1. Principles of Management by Koontz and ODonnel.
2. Production and Operations Management by Everette Adamand Ronald
Ebert.
3. Operations Management by John McClain and Joseph Thames.
4. Industrial Engineering and Production Management by Tulsa, S.
Chand and Co.

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 VNR VIGNANA JYOTHI INSTITUTE OF ENGINEERING & TECHNOLOGY
(Autonomous)
DEPARTMENT OF MECHANICAL ENGINEERING

III BTech, II Semester (Mechanical Engineering)

Subject : UNCONVENTIONAL MACHINING PROCESSES
Subject Code : 13MED033
Academic Year : 2016 – 17
Number of working days : 90
Number of Hours / week : 4
Total number of periods planned: 35
Name of the Faculty Member: Ch.Priyadarsini / Ch.Hima Bindhu

Course Objectives:

 Understand the classification of various Non-Traditional machining

processes and their applicability to various metals, non - metals &
alloys
 Understand the working principles of mechanical energy based
material removal processes
 Understand the Working principles of thermal energy and electrical
energy based material removal processes
 Understand the working
Course Outcomes:
Students will be able to:

 Gain the knowledge on various Non-Traditional machining methods

which are applicable for difficult-to-cut materials, defense and
aerospace sectors
 Decide on the process parameters to be adopted and applicability of
various materials that are suitable for mechanical energy based
machining processes
 Decide on the process parameters to be adopted and applicability of
various materials that are suitable for electrical and thermal based
machining processes
 Decide on the process parameters to be adopted and applicability of
various materials that are suitable for chemical and electro-chemical
energy based machining processe

UNIT : I

Syllabus:
INTRODUCTION Unconventional Machining Process, Need, Classification,
Brief overview of all techniques, Study of material removal phenomena.
Learning Objectives:
After completion of the unit, the student must able to:
 Explain what are different types of Unconventional Machining
processes and what is need of them.

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  Explain what are the different classifications of UCMP.
 Explain overall techniques used in UCMP
 Explain phenomena of material removal.

Lecture Plan
S.No. Description of Topic No. of Hrs. Method of
Teaching
Unconventional Machining Process,
1. 1st hours Black board
Need
Classification, Brief overview of all
techniques, Study of material Black board +
2. 2 hour
removal phenomena. Video

Assignment – 1

1. Differences between conventional machining and unconventional

machining process.
2. Classification of Non-traditional machining process?

UNIT : II
Syllabus:
MECHANICAL ENERGY BASED PROCESSES Abrasive Jet Machining –
Water Jet Machining – Abrasive Water Jet Machining- Ultrasonic Machining
(AJM, WJM, AWJM, USM). Working Principles – equipment used – Process
parameters – MRR – Applications.
Learning Objectives:
After completion of the unit, the student must able to:
 Understand what is Abrasive Jet Machining, principle used and
process parameters to be considered and applications.
 Explain in detail Water Jet Machining.
 Explain Abrasive Jet Machining.
 Explain Abrasive Water Jet Machining.
 Explain Ultrasonic Machining
Lecture Plan

S.No. Description of Topic No. of Hrs. Method of

Teaching
Abrasive Jet Machining Working
Principles – equipment used –
3,4& 5 th Black board
1. Process parameters – MRR –
hours +PPT
Applications.

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 – Water Jet Machining Working
Principles – equipment used – Black
2. 6&7th hours
Process parameters – MRR – board+video
Applications
Abrasive Water Jet Machining
Working Principles – equipment
Black
3. used – Process parameters – MRR – 8&9 hours
board+video
Applications.

Ultrasonic Machining Working

Principles – equipment used –
Black
4. Process parameters – MRR – 10,11,12&13
board+video
Applications.

Assignment – 2
1. Explain the Abrasive Water Jet Machining in detail
2. Explain the Ultrasonic Machining in detail.

UNIT : III
Syllabus:
ELECTRICAL ENERGY BASED PROCESSES Electric Discharge Machining
(EDM) - working Principles-equipments-Process Parameters-MRR- electrodes
Used – Power Circuits – Dielectric – Flushing – Applications, Wire Cut EDM-
Applications.

Learning Objectives:
After completion of the unit, the student must able to:
 Understand the concept of Electric Discharge Machining,principles
and process parameters.
 Explain Dielectric – Flushing – Applications.
 Understand the Power Circuits in EDM .
 Understand the concept of Wire Cut EDM.
Lecture Plan
S.No. Description of Topic No. of Hrs. Method of
Teaching
Electric Discharge Machining (EDM)
- working Principles. Black
1. 14 hours
board+video
Process Parameters-MRR- electrodes 15&16
2. Black board + ppt
Used. hours

10
 electrodes Used – Power Circuits 17&18
3. Black board + ppt
hours
4. – Dielectric – Flushing – Applications 19 Black board + ppt
Wire Cut EDM- Applications Black
20
board+video
Assignment – 3
1. Explain Electric Discharge Machining in detail?
2. Explain Power Circuits in EDM
3. Write thae applications of EDM
4. Explain Wire cut EDM process in detail
5. Write tha applications of Wire cut EDM

UNIT : IV

Syllabus:
CHEMICAL AND ELECTRO-CHEMICAL ENERGY BASED PROCESSES
Chemical Machining and Electro-Chemical machining (CHM and ECM)-
Etchantsmaskants -techniques of applying maskants-Process Parameters –
MRR-Applications- Principles of ECM-equipments-MRR-Processes
Parameters

Learning Objectives:
After completion of the unit, the student must able to:
 Understand the Chemical & Electro Chemical Energy based processes.
Lecture Plan
S. Description of Topic No. of Hrs. Method of
No. Teaching
Chemical Machining.
Etchantsmaskants -techniques of 21&22nd Black board +
1.
applying maskants-Process hours Video
Parameters – MRR-Applications
Principles of ECM-equipments-
23,24&25th Black board +
2. MRR-Processes Parameters
hours Video
Assignment – 4
1.Explain the process of Chemical machining.
2. Explain Electro Chemical Machining in detail.
UNIT : V

Syllabus:
THERMAL ENERGY BASED PROCESSES Laser Beam Machining (LBM),
Plasma Arc Machining (PAM) and Electron Beam Machining (EBM),
Principles-Equipment-Process Parameters - Applications.
Learning Objectives:
After completion of the unit, the student must able to:

 Understand Laser Beam Machining

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 Understand Plasma Arc Machining
 Understand Electron Beam Machining

Lecture Plan

S. Description of Topic No. of Hrs. Method of

No. Teaching
Laser Beam Machining (LBM)
Principles-Equipment-Process Black board +
1. 26&27th hours
Parameters - Applications. ppt

Plasma Arc Machining (PAM) Black board +

28&29&30hours
ppt+video
Electron Beam Machining (EBM),
Principles-Equipment-Process Black board +
2. 31&32 hours
Parameters - Applications. ppt+video

Assignment - 5
1. Explain the process of LBM.
2. Explain the process of PAM.
3. Explain the process of EBM.

EXTRA TOPICS
33to 35 hours : Other information related to subject(MAF,AFM)
TEXT BOOKS:
1. Advanced Machining Processes by Vijay K. Jain; Publisher: Allied
Publishers. REFERENCES:
2. Nontraditional Manufacturing Processes by Benedict. G. F; Publisher:
Marcel Dekker.
3. Advanced Methods of Machining by McGeough; Publisher: Chapman
and Hall, London.
4. Unconventional Machining Processes by P. K. Mishra; Publisher:
Narosa.

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 VNR VIGNANA JYOTHI INSTITUTE OF ENGINEERING & TECHNOLOGY
(Autonomous)
DEPARTMENT OF MECHANICAL ENGINEERING

ACADEMIC PLAN
Year & Sem. : IV-BTech, II-Semester (Mechanical
Engineering)
Subject : METAL CASTING TECHNOLOGY
Subject Code : 13MED042
Academic Year : 2016 – 17
Number of working days : 90
Number of Periods per week :4
Total number of periods planned : 40
Name of the Faculty Members : Dr. N. Kiran Kumar & S.N.S.Sai Hari

Course Objectives:
 Understand various casting processes and their application
 Understand the use of patterns and their design
 Understand the design of runner, riser and gating systems and
allowances to be provided.
Course Outcomes:
Students will be able to:
 Select appropriate casting process for a component meeting design
specifications.
 Design a part for casting and design a pattern based on the process
 Apply dynamic programming problem solving and simulation models.
 Assess the castings for defects and apply remedies to the defects
found through inspection.
UNIT – I PATTERN AND FOUNDRY SAND (8periods)
Syllabus:
Foundry as manufacturing process, Types of patterns, Pattern Materials,
Pattern Allowances, Pattern Layout, Pattern making, Various sands, Testing
of foundry sand: Strength Permeability, Moisture Content.
Learning Objectives:
After completion of the unit, the student must able to:
 Explain different types of patterns, pattern materials & Allowances.
 Explain Pattern layout and making of patterns
 Explain different types of sands and testing of foundry sands.
Lecture Plan:
No. of Method of
S.No. Topic
Periods Teaching
Introduction to MCT and Foundry Black Board +
1 2
as manufacturing process PPT
Types of patterns, Pattern Black Board +
2 2
Materials PPT
Pattern Allowances, Pattern Black Board +
3 2
Layout, Pattern making PPT

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 Various sands, Testing of foundry Black Board +
4 sand: Strength Permeability, 2 PPT
Moisture Content.
Assignments:
1. Explain in brief “Types of patterns, Pattern Materials, Pattern
Allowances”
2. Explain in brief “Various sands, testing of foundry sand”

UNIT – II MOULDING METHODS (8periods)

Syllabus:
Moulding methods: Green sand moulding, dry sand moulding, no bake
moulding, shell moulding, Investment casting, Permanent moulding, die
casting and Centrifugal casting. Modern moulding methods: Rheocasting,
Thixocasting and Squeeze casting.
Learning Objectives:
After completion of the unit, the student must able to:
 Explain different types of Moulding methods (Traditional and New
Methods)
Lecture Plan:
No. of Method of
S.No. Topic
Periods Teaching
Green sand moulding, Dry sand Black Board +
1 2
moulding, No bake moulding PPT
Shell moulding, Investment Black Board +
2 2
casting, Permanent moulding PPT
Die casting and Centrifugal Black Board +
3 2
casting PPT
Rheocasting, Thixocasting and Black Board +
4 2
Squeeze casting. PPT
Assignments:
1. Briefly explain Different Methods of Casting.
2. Briefly explain different Modern moulding methods.

UNIT – III GATING AND RISERING (7periods)

Syllabus:
Solidification, Gates and their functions, design of gating system, Risers and
their functions, design of Risers.
Learning Objectives:
After completion of the unit, the student must able to:
 Explain Solidification
 Explain Gates and their functions and design of gating system
 Explain Risers and their functions and design of Risers.
Lecture Plan:
No. of Method of
S.No. Topic
Periods Teaching
Black Board +
1 Solidification 1
PPT

14
 Gates and their functions, design Black Board +
2 3
of gating system PPT
Risers and their functions, design Black Board +
3 3
of Risers. PPT
Assignments:
1. Explain Gating
2. Explain Risering

UNIT – IV MELTING FURNACES (7periods)

Syllabus:
Constructional details, Operation of crucible furnaces, Reverberatory
furnaces- Cupola, Rotary furnace – Core type and Coreless type, Induction
furnaces - Arc furnace (direct and indirect arc furnaces).
Learning Objectives:
After completion of the unit, the student must able to:
 Explain Constructional details and Operation of crucible furnaces
 Explain Constructional details and Operation of Reverberatory
furnaces
 Explain Constructional details and Operation of Rotary furnaces
 Explain Constructional details and Operation of Induction furnaces-
Arc furnaces
Lecture Plan:
No. of Method of
S.No. Topic
Periods Teaching
Black Board +
1 Crucible furnaces 1
PPT
Black Board +
2 Reverberatory furnaces- Cupola 2
PPT
Rotary furnace – Core type and Black Board +
3 2
Coreless type PPT
Induction furnaces - Arc
Black Board +
4 furnace (direct and indirect arc 2
PPT
furnaces)
Assignments:
1. Explain crucible furnaces, Reverberatory furnaces
2. Explain Rotary furnace, Induction furnaces

UNIT – V FETTLING AND INSPECTION (8periods)

Syllabus:
Removal of gates and risers, Grinding, Shot blasting and finishing,
Inspection, Casting defects, Remedies.
Learning Objectives:
After completion of the unit, the student must able to:
 Explain how to Remove gates and risers
 Explain Grinding, Shot blasting and finishing of castings.
 Explain how to inspect the castings.
 Explain different casting defects and Remedies.
Lecture Plan:

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 No. of Method of
S.No. Topic
Periods Teaching
Black Board +
1 Removal of gates and risers 2
PPT
Grinding, Shot blasting and Black Board +
2 2
finishing PPT
Black Board +
3 Inspection of castings 2
PPT
Black Board +
4 Casting defects, Remedies. 2
PPT

Assignments:
1. How to remove gates and risers?
2. What are the different inspection techniques used for castings?
Explain each in brief.
3. What are the different casting defects and their remedies?

OTHER TOPICS BEYOND THE SYLLABUS (2periods)

***

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